Pile fabric and method of making the same



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Patented Feb. 4, 1936 UNITED STATES PATENT OFFICE PILE FABRIC AND METHODOF MAKING THE SAME Application April 12, 1933, Serial No. 665,725

4 Claims.

My invention is a pile fabric having a ground or back with which pileloops or tufts of unequal length or height are interlaced to formirregular face, and the method of weaving such fabrics.

In fabric embodying my invention,- the ground or back contains weftswith which pile warps are interlaced so that each pile warp formsalternately long and short pile loops. Preferably the pile warpsinterlaced in a ground are grouped in pairs loops may be left uncut toform a frieze type fab-- ric or may be cut to form cut pile tufts ofunequal lengths.

Such fabrics may be woven double, in accordance with my invention, upona loom having three sets of pile loop gauges, such as wires or cordsextending warpwise of the loom; one set of gauges being disposed in asubstantially horizontal plane between the other two sets of gauges. Theintermediate set of gauges supports and aids in the formation of longloops of both a top fabric and a bottom fabric. Theupper set of gaugessupports and aids in the formation of short loops for the top fabric,and the lower set of gauges supports and aids in the formation of shortloops for the lower fabric. Preferably a double shuttle loom is utilizedin weaving the fabrics double and pairs of wefts are laidsimultaneously, but a single shuttle loom may be employed.

In weaving my novel fabrics double, there are utilized ground warps foreach fabric, pile warps for each fabric and pairs of picks positionedone above the other. The pairs of picks are laid in a cycle in which, itmay be considered, one pick of the first pair is interlaced with theground warps and all the pile warps of the top fabric and the other pickof the first pair is interlaced with the ground warps and all the pilewarps of the bottom fabric. One weft of the second pair supports shortloops formed by certain pile warps of the bottom fabric and the otherweft of the second pair supports long loops formed by other pile warpsof the bottom fabric. The respective 'wefts of the third pair interlacewith the ground warps of the top fabric and bottom fabric. respectively.One weft of the fourth pair supports long loops formed by certain pilewarps of the top fabric and the other weft of the fourth pair supportsshort loops formed by other pile warps of the top fabric. The cycle isthen repeated but with the pile warps which formed long loops in thefirst sequence forming short loops in the second sequence, and viceversa.

The characteristic features and advantages of my method and the productthereof will further appear from the following description and theaccompanying drawing in illustration thereof.

In the drawing, Fig. l is a longitudinal sectional view illustratingdiagrammatically the arrangement of yarns and gauges in the weaving ofdouble fabric in accordance with my invention and Fig. 2 is a graphillustrating diagrammatically the shedding of warps and top and bottomgauge sets during the picking of the wefts of a complete series.

As illustrated in the drawing, the fabrics are woven in duplicate on adouble shuttle loom having a set of upper gauge wires A s'upportedattheir left hand end (Fig. 1) by the shedding mechanism of the loom, aset of lower gauge wires B supported at their left hand ends (Fig. 1) bythe shedding mechanism of the loom, and a set of stationary gauge wiresC disposed in a horizontal plane between sets A and B.

By the utilization of such mechanism and of my improved method, theremay be produced a top fabric and a bottom fabric each having a groundand long and short pile loops. Such fabrics separate from one another asthey weave downofi the gauges A, B and C and towards the right (Fig. 1)and are taken off by the pin rollers of the loom.

The weaving of the top fabric involves the shedding of gauges A, ofground warps A and A and of pile warps A and A The weaving of the bottomfabric involves the shedding of. the gauges B, of ground warps B and Band of pile warps B and B At the beginning of the weaving of the fabricfragment shown in Fig. 1, (starting at the right) the shedding mechanismelevates the warps A A A A and gauge B and depresses warps A B B B andgauge A so as to permit the simultaneous laying of the pick 5 ininterlacing relation with the ground warps and pile warps of the topfabric and of the pick 5' in interlacing relation with the ground warpsand pile warps of the bottom fabric.

Before the next picking action, the shedding mechanism elevates thewarps A B gauge A, depresses the warps B gauge B, moves the warps H tointermediate position and leaves znaining warps as they previously were.When the shuttles lay the picks 8" and 9 they are supported respectivelyon the gauges C and i3 and support respectively the warps B and B andform respectively long loops 0 and short loops b on the bottom fabric.

The shedding mechanism then elevates the warp B and gauge B, depressesthe warp A and gauge A moves the warps A A and B to intermediateposition, leaving the remaining warps as they were on the previouspicking motion. The laying of the picks Hand 1' interlaces themrespectively with the ground warps A and A and. with the ground warps Band B On the next shedding movement, the warps A and gauges A areelevated, the warps B A BA 13 and gauges B are depressed, and theremaining warps are left as they were on th ,st previous picking motion.The piclzor weft l. is then laid and is supported against the gauges A.supports the short loops formed the warps A. The companion pick or weftlaid supported against the gauges C and supports the long loop c formedby the warp The next shedding motion elevates warns B A A and the gaugesl3; depresses as. -o A and the gauges A and. leaves the remaining warpsin their last preceding'position. The I 8 is then laid and interiacesbetween the grcun warps A and A and anchors the warps A and A in theground. Simultaneously or sequentially the pick 9 is laid and interlaceswith the ground warps B B and anchors the pile warps B and B in theground of the bottom fabric.

During or after the beat-up of the picks 9 and 8", the shedding motionelevates the warps A, B and gauges A; depresses the warps l3 and gaugesB; and moves the warps B to an intermediate position, the remainingwarps being left in their last preceding position. The pick or weft IIIis then laid and is supported by the gauges C and supports the'longloops b formed by the warps B Simultaneously or sequentially therewiththe pick ill is laid, is supported by the gauges B, and supports theloop 0" formed by the warps B There is thus formed across the fabric asecond row of long and short loops on the bottom fabric, the warps whichform the small loops of the first row forming the long loops of thesecond row, and vice versa.

The next shedding motion elevates the warps B and the gauges B;depresses the warps A and gauges A; moves the warps A A and B to anintermediate position, and leaves the remaining warps in their lastpreceding position. The pick iiis now laid to form a ground weft betweenthe ground warps A and A of the top fabric and the pick ii isconcurrently or sequentially laid to form a weft interlaced with theground warps B and B of the bottom fabric.

The next movement of the shedding mechanism elevates the warps A and thegauges A; depresses the warps B, A B, B and gauges B and leaves theremaining warps in their last previous position. The pick Ii." is thenlaid to form a face weft resting against the gauges A and supporting theshort loo s a formed by the warps The pick 52" is cccu "ently orsequentially laid to form a, face weft resting against the gauges C andsupporting the loops 0" formed by the warps n There are thus formedacross the top fabric a second row of long and short loops, the warpswhich form the long loops of the first row forming the short loops ofthe second row, and vice versa.

After the fabrics pass oil the free ends of the gauges they separate andthe wefts connecting the selvages of the two fabrics may be readily cutand the face Wefts pulled ii. desired.

By my invention I am enabled to produce rapidly and economically fabricshaving long and short loops providing a good coverage or the ground witha minimum use of pile yarns, and if desired, the loops may be cut so asto provide pile tufts or different lengths simulating the uneven lengthsof the hairs of natural fur.

"' described my invention, 1' claim- .i'abric comprising a groundcontain- ,rouncl wefts and pairs of pile warps intertnerein, each pilewarp forming alternatemg loop a short pile loop and the short long loopof the warps sucl ground Wei 2. El. pile fabric comprising a groundincluding weft threads, pile warps looped around weft threads aforesaidand forming rows of loops of unequal lengths between said weft threads,8. ground weft over which each of said rows is looped and face wei'tssupporting respectively a row of long loops and a row of short loops.

In the weaving of double fabrics, the steps which consist in laying yarnto form a weft in each of a pair of spaced grounds, next laying yarn toform Wefts supporting respectively pile loops of different lengthsinterlaced in one of said grounds only, next laying yarn to form a weftin each of said pair of grounds, and next laying yarn to term weftssupporting respectively pile loops of different lengths interlaced inthe other of said grounds only.

4. In the weaving of double fabrics on three sets of pile loop gaugesarranged with one set 01' gauges between the other two sets of gauges,the steps which consist in laying yarns to form a weft above the upperset of gauges and a weft below the lower set of gauges, interlacing witheach of said wefts ground warps and pile warps. laying yarns to form aweft between the intermediate set and upper set of said gauges and tothe: warp of such pair, and the nr being looped under the same form aweft between the intermediate set and- .to form a weft between theintermediate set and upper set of said gauges and to form a weft betweenthe intermediate set and the lower set of said gauges and interlacingwith said last named wefts pile warps interlaced with the other of saidfirst named wefts.

FRANK M. KAUFMAN.

I one we oi pair being aligned with a

